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Abstract:

A method of connecting a component to a molded article may include
disposing a component adjacent to a wall of the article being molded,
overlapping a portion of the component with a portion of the wall of the
article being molded while the wall is still at least partially molten,
and permitting the wall of the article being molded to cool with said
portion of the component still overlapped by the wall. Preferably, a
portion of the component is overlapped on two sides by the wall of the
article being molded to firmly retain the component relative to the
article after the article is formed. The article may be a receptacle, or
any other object, as desired.

Claims:

1. A method of connecting a component to a molded article, comprising:
disposing a component adjacent to a wall of the article being molded;
overlapping a portion of the component with a portion of the wall of the
article being molded while the wall is still at least partially molten,
so that at least a portion of the component is received between two
portions of the wall to connect the component to the wall; and permitting
the wall of the article being molded to cool with said portion of the
component still overlapped by the wall to maintain the connection of the
component to the wall.

2. The method of claim 1 wherein overlapping a portion of the component
with a portion of the wall is accomplished by moving at least one tool
relative to the component so that the tool engages a portion of said wall
and moves said portion of the wall until said portion of the wall
overlaps a portion of the component.

3. The method of claim 1 wherein the component includes a void and the
portion of the wall is moved at least partially into the void during the
overlapping step to connect the component to the wall.

4. The method of claim 1 wherein the component includes a flange and the
portion of the wall is folded around the flange so that portions of the
wall overlies two opposed sides of the flange and the flange is trapped
between said portions of the wall.

5. The method of claim 2 wherein said at least one tool includes at least
two spaced apart tools each adapted to move relative to the component a
different portion of the wall of the article.

6. The method of claim 1 wherein disposing a component adjacent to a wall
of the article being molded is accomplished by pressing an end surface of
the component against the wall and displacing a portion of the wall and
overlapping a portion of the component with a portion of the article
being molded is accomplished after said end surface of the component is
pressed against the wall.

7. A system for attaching a component to a receptacle, comprising: a mold
defining part of a forming surface against which the receptacle is
molded, and at least one tool cavity open to the forming surface; and a
tool disposed at least partially within the tool cavity and movable
relative to the forming surface from a retracted position to an advanced
position, the tool having a working surface that engages material forming
the receptacle at least when the tool is moved to its advanced position
to overlap a portion of the component with material forming the
receptacle to hold said component in position relative to the receptacle.

8. The system of claim 7 wherein the mold includes a recess defining part
of a forming surface against which the receptacle is molded, and said
tool cavity is open to the recess with the tool moveable within the tool
cavity and relative to the recess to move material against a portion of
the component to hold said component in position relative to the
receptacle.

9. The system of claim 8 wherein the recess is sized to receive an end
surface of the component therein, with material forming the receptacle
disposed adjacent to the end surface and within the recess.

Description:

REFERENCE TO COPENDING APPLICATION

[0001] This application is a divisional of U.S. application Ser. No.
12/964,178 filed Dec. 9, 2010 and claims the benefit of U.S. Provisional
application Ser. No. 61/285,700 filed Dec. 11, 2009, which are
incorporated herein by reference in their entirety.

TECHNICAL FIELD

[0002] The present disclosure relates generally to an arrangement for
mounting a component relative to another component.

BACKGROUND

[0003] Receptacles may include components within their interior volume, or
connected to their exterior. For example, fuel tanks for vehicles
typically include a fuel pump, one or more valves, a fuel level sensor
and perhaps other components arranged within the fuel tank. The
components may be mounted on a carrier or other support that is placed in
the fuel tank, or the components may be attached to a flange that is
secured on an already formed fuel tank wall, such as by a clamp or
threaded connection.

SUMMARY

[0004] A method of connecting a component to a molded article may include
disposing a component adjacent to a wall of the article being molded,
overlapping a portion of the component with a portion of the wall of the
article being molded while the wall is still at least partially molten,
and permitting the wall of the article being molded to cool with said
portion of the component still overlapped by the wall. Preferably, a
portion of the component is overlapped on two sides by the wall of the
article being molded to firmly retain the component relative to the
article after the article is formed. The article may be a receptacle, or
any other object, as desired.

[0005] A method of forming a molded article with a component attached to
the article may include several steps, including:

[0006] providing a molten parison into a mold cavity defined by at least
two molds;

[0007] forming the parison into the mold cavity;

[0008] severing at least a portion of the parison;

[0009] separating at least two of the molds to also separate portions of
the severed parison and expose an interior of the parison;

[0010] disposing a component adjacent to a wall of the parison;

[0011] overlapping a portion of the component with a portion of the wall
of the parison while the wall is still at least partially molten; and

[0012] closing said at least two of the molds to define an enclosed mold
cavity and join together again the severed portions of the parison. In
this way, the parison can be opened to permit one or more components to
be received within an interior of the parison and closed to seal the
severed portions of the parison together for final forming or curing.

[0013] In one form, a system for attaching a component to a receptacle may
include a mold defining part of a forming surface against which the
receptacle is molded, and at least one tool cavity open to the forming
surface, a tool disposed at least partially within the tool cavity and
movable relative to the forming surface from a retracted position to an
advanced position. The tool may have a working surface that engages
material forming the receptacle at least when the tool is moved to its
advanced position to overlap a portion of the component with material
forming the receptacle to hold said component in position relative to the
receptacle.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The following detailed description of exemplary embodiments and
best mode will be set forth with reference to the accompanying drawings,
in which:

[0015] FIG. 1 is a cross-sectional view of one exemplary implementation of
a blow molding apparatus that may be used to form a receptacle;

[0016] FIG. 2 is a cross-sectional view of the blow molding apparatus of
FIG. 1 illustrating a component positioned between separated halves of
the parison and blow mold, and being connected to the parison;

[0017] FIG. 3A is an fragmentary side view, partially in section, showing
a component within a recess of a mold, and tools prior to engaging the
parison;

[0018] FIG. 3B is a view similar to FIG. 3A, showing tools engaging the
parison to overlap a portion of the component with the parison;

[0019] FIG. 4 is a fragmentary sectional view of one exemplary parison
construction;

[0021] FIGS. 11 and 12 are diagrammatic plan views showing different
implementations of a component.

Detailed Description of Presently Preferred Embodiments

[0022] Referring in more detail to the drawings, FIG. 1 illustrates a blow
molding apparatus 10 that may be used to form an article from a molten
parison 12. In one implementation, the article may be a receptacle, such
as a fuel tank used in a vehicle fuel system. Of course, the receptacle
could be used to contain something other than fuel. In the example of a
fuel tank, the fuel tank may include one or more walls 14 defining an
internal volume 16 in which the fuel is contained. The fuel tank wall(s)
14 may be formed of any suitable material(s). In one form, the fuel tank
may be formed from several layers of polymeric materials, in a so-called
"multi-layer" fuel tank. As shown in FIG. 4, the various layers may
include one or more structural layers which may form inner and outer
layers 17, 18 formed of HDPE or the like, one or more adhesive layers 20
and one of more barrier layers 22 having a desired resistance to
permeation therethrough of hydrocarbon or other vapors or liquids
associated with the fluid contained within the fuel tank. Exemplary
barrier layer materials include nylons and EVOH (ethylene vinyl alcohol),
although others may be used. Alternatively, the tank could be formed from
a single material, or could have layers in addition to or other than
those specifically noted herein.

[0023] In forming a hollow receptacle such as a fuel tank, the parison may
be introduced into a blow mold apparatus 10 having a mold cavity defined
by one or more molds 24, 26 collectively defining a forming surface 28
against which the parison 12 is inflated by introduction of pressurized
gas through a blow pin 30. In one implementation, the apparatus and
method set forth in U.S. patent application Ser. No. 12/491,964 filed on
Jun. 25, 2009, could be utilized, and the disclosure of that application
is incorporated herein by reference in its entirety. In general, the
parison 12 may be initially blow molded, than separated into two halves,
such as by suitable cutters 32. The molds 24, 26 with the severed parison
halves therein, can then be opened, as shown in FIG. 2. In this position,
components can be inserted between the separated mold and parison halves,
prior to joining together again the parison halves to finally form the
receptacle. In this manner, various components 34 can be disposed within
an interior volume of the receptacle, or, with appropriate modification
of the molds 24, 26, could be disposed on or otherwise carried by an
exterior of the receptacle.

[0024] In one implementation, as shown in FIGS. 2, 3A and 3B, at least one
portion of the mold 24, 26 includes a recess 36 adapted to receive at
least a portion of a component 34 to be connected to the receptacle. The
mold 24, 26 may also include one or more openings or tool passages 38
that are open to the recess 36. The recess 36 may be formed in the
forming surface 28 of the mold, and may define part of the forming
surface of the mold. The tool passages 38 may be formed through the mold
24, 26 so that they open directly (or axially) to the interior of the
mold. Or, as shown in FIGS. 3A and 3B, the tool passages 38 may be blind
bores or otherwise terminate to open generally radially to the recess 36
and may define an inwardly extending flange 40, as shown in

[0025] FIGS. 3A and 3B. In this form, the tool passages 38 may be formed
from an opposite side of the mold 24, 26 as the forming surface 28, and
may overlap, or intersect, or otherwise open or be opened into the recess
36. The recess 36 may be formed by a right cylindrical blind bore, or of
any other shape and orientation, and the tool passages 38 may be formed
by a straight bore open and parallel to the recess. Of course, other
arrangements may be used.

[0026] In one implementation, such as shown in FIGS. 2, 3A and 3B, a
component 34 may include an end surface 37 and a radially outwardly
extending flange 42 that defines part of an undercut, recess or void 44
adjacent to the flange. The component 34 may include a second flange 46
or other surface that defines a neck 48 between the two flanges 42, 46.
The recess 36 in the mold 24, 26 may be sufficiently deep to enable the
flange 42 to be at least partially received in the recess 36 and position
the void 44 of the component 34 at least partially in the recess 36. The
component 34 could have substantially any shape. Some representative
shapes are shown, for example, in FIGS. 3, 11 and 12, but many others are
possible. The flange 42 need not be circumferentially continuous. Indeed,
no flange 42 or 46 need be provided. The void 44 provided in the
component 34 in which the parison material is at least partially moved,
need not be circumferentially continuous or extend all the way around the
component. Rather, the void could include one or more cavities,
undercuts, grooves, slots or the like, which could be provided in the
component to receive some of the parison material as moved therein by the
tools. And such voids can be spaced apart about the exterior of the
component in any desired arrangement.

[0027] One or more tools 50 may be disposed in the tool passage 38 (or
passages), adjacent to the recess 36, and movable relative to the recess
36. Each tool 50 may include an arm 52 and a working end 54 carried by
the arm 52 and adapted to engage the parison 12. The tools 50 may be
moved from a first position, retracted away from the component as shown
in FIG. 3A, and a second position advanced toward the component as shown
in FIG. 3B. The tools 50 may be driven between and to their retracted and
advanced positions by one or more actuators 56. Of course, the tools 50
can be manually manipulated. The tools 50 may be driven along a linear
path generally perpendicular to an axis 58 of the recess 36, or they may
be driven along any suitable path between retracted and advanced
positions as generally discussed above (for example, they may be pivoted
along an arcuate path, rotated or some combination of multiple paths of
movement, if desired).

[0028] As best shown in FIGS. 3A and 3B, insertion of the component 34
into the recess 36 engages the end surface 37 of the component with the
parison and may also displace the adjacent portion of the parison 12,
which is still at least partially molten and pliable, into the recess 36
and next to the tools 50. Thereafter, when the tools 50 are advanced from
their refracted position, shown in FIG. 3A, to their advanced position,
shown in FIG. 3B, a portion of the parison 12 is moved against the
component 34 and/or into the void(s) 44 of the component 34 by the tools
50 so that a portion of the component 34 is overlapped by a portion of
the parison wall 12. That is, a portion of the parison wall is folded
over a portion of the component so that at least a portion of the
component 34 is sandwiched or trapped between two portions of the parison
wall, with the parison wall disposed adjacent opposed surfaces or sides
of the wall of the component. The parison material may be sufficiently
heated to affect a bonding or welding of the parison material to the
material of the component 34 which may be formed of a suitably compatible
polymeric material. Of course, such welding or bonding may not be
necessary to effectively connect the component 34 to the parison 12 and
finally formed receptacle in view of at least the manner in which the
parison wall is overlapped about the component.

[0029] Upon final forming and cooling of the parison 12, the component 34
remains at least partially trapped or overlapped by the parison wall to
retain the position of the component 34 relative to the finished
receptacle. Again, in the implementation shown in FIGS. 2, 3A and 3B, the
component 34 is attached adjacent to an interior surface of the parison
wall 12 so that the component 34 extends into and communicates with the
internal volume of the receptacle. After a desired time in their advanced
position, the tools 50 are moved to their retracted position so that the
working ends 54 of the tools 50 are clear of the parison 12 and the
component 34 to permit removal of the parison 12, with the component 34
attached thereto, from the recess 36 and the mold 24, 26. The parison
halves can then be joined together, such as by welding, to form the
receptacle or other article, or, the parison halves can be joined before
the tools 50 are moved to their retracted position, or at any other time.

[0030] As shown in FIGS. 5 and 6, one or more tools 50 may be provided to
displace portions of the parison relative to the component, to move
spaced apart portions of the parison into one or more voids of the
component to more securely connect the component to the parison. While
two and three tools 50 are shown, substantially any number of tools 50
may be used as desired to effect a connection between the component 36
and the parison 12. The tools 50 may be evenly or unevenly
circumferentially spaced, as desired. FIGS. 7-9 illustrate tools having
differently shaped working ends 54 or surfaces which may displace the
parison material in different manners relative to the component. Any
desired shape of the working ends 54 may be used in addition to using any
desired number of tools to provide a desired movement of the parison
material and entrapment of the component 34 in the parison material. In
using tools 50 with differently shaped end surfaces, only a very minor
portion of the component may be overlapped by the parison material, or
substantially all of the flange (or other portion of the component) may
be trapped within the parison material, as desired. Still further, FIG.
10 illustrates that the working ends 54 may have a different shape or
configuration in a generally axial direction, that is, they may have
greater thickness to move a greater axial length of the parison material
relative to the component as compared to a relatively thin, flat working
surface. In this way, the component 34 and the tool(s) 50 can be
constructed in a wide variety of configurations and arrangements to
facilitate attaching the component to the parison wall during the molding
process.

[0031] Accordingly, a method of connecting a component to a molded
article, may include disposing a component adjacent to a wall of the
article being molded, folding a portion of the parison wall over a
portion of the component while the wall is still at least partially
molten, and permitting the wall of the article being molded to cool with
a portion of the component still overlapped by the wall. The molded
article can be of substantially any shape and arrangement and need not be
hollow or entirely hollow. The description of the exemplary blow-molded
receptacle is not intended to limit the applications and arrangements to
which the method and apparatus can be applied. The component can take
many forms, include a bracket or other device that merely supports
another component.

[0032] While the forms of the invention herein disclosed constitute
presently preferred embodiments, many others are possible. For example, a
recess 36 in the mold 24, 26 may not be needed. If no recess 36 is
provided, the tools 50 may be initially retracted until the component is
disposed adjacent to the parison wall, and then the tools may be advanced
toward the component to move portion of the parison wall around an edge
of the component and then inwardly to fold the material into a void or
around an edge of the component. Thereafter, the tool may be retracted to
its initial position. The tool may advanced and retracted linearly (e.g.
a first linear movement forward and a second linear movement inward
toward the component), along a pivoted or arcuate path, or in any other
suitable way. It is not intended herein to mention all the possible
equivalent forms or ramifications of the invention. It is understood that
the terms used herein are merely descriptive, rather than limiting, and
that various changes may be made without departing from the spirit or
scope of the invention.

Patent applications by Peter Grauer, Steinweiler DE

Patent applications by TI Automotive Technology Center GmbH

Patent applications in class Mechanically securing parts together by reshaping joint portion only

Patent applications in all subclasses Mechanically securing parts together by reshaping joint portion only